Electrical duplex connector having an integrally formed connector body with a frustro-conical retaining ring and unidirectional cable retainers

ABSTRACT

This disclosure is directed to electrical connectors, and more specifically to a duplex or multiplex electrical connector having an integrally formed connector body having an inlet end portion defining a plurality of passageways for receiving a cable, and an outlet end portion wherein the outlet end portion is provided with an outer surface that slopes downwardly toward the outlet opening and having a complementary sloping or frustro-conical, snap fit, outer, retaining ring with locking tangs and grounding tangs for snap locking the outlet end portion of the connector to an electric box or panel, and including a unidirectional cable retaining sleeve disposed within each of the inlet bores or passageways which are firmly secured therein in a predetermined oriented position relative to the respective passageway, and having a non-conducting bushing sandwiched between the outlet end opening and the outer frustro-conical retaining ring.

RELATED APPLICATIONS

This application is a continuation in part of application having Ser.No. 11/903,410 filed Sep. 21, 2007 which is a continuation in partapplication of application Ser. No. 11/501,131 filed Aug. 8, 2006 nowU.S. Pat. No. 7,488,905 for Electrical Connector With Outer RetainerRing and Internal Unidirectional Conductor Retainer, which is acontinuation in part application of application Ser. No. 11/403,099filed Apr. 12, 2006 for Snap Fit Electrical Connector Assembly WithFrustro Conical Retainer Ring And Internal Unidirectional Snap Fit WireConductor Retainer, now U.S. Pat. No. 7,151,223, which is a continuationin part application of application Ser. No. 11/400,606 filed Apr. 7,2006 for Electrical Connector With Frustro Conical Snap Fit RetainerRing Constructed To Enhance The Insertion Of The Connector Through AKnockout Hole Of An Electric Box, now U.S. Pat. No. 7,154,042, which isa continuation in part application of application Ser. No. 11/364,435filed Feb. 28, 2006 for Snap-Fit Electrical Connector Assembly ForFacilitating The Connection of the Electric Connector Assembly To AnElectric Box, now U.S. Pat. No. 7,205,489, which is a continuation inpart of application Ser. No. 11/258,990 filed Oct. 26, 2005, now U.S.Pat. No. 7,057,100, which is a continuation in part of application Ser.No. 11/151,374 filed Jun. 13, 2005 for Snap Fit Electrical ConnectorAssembly With Conical Outer Snap Fit Retainer And One Or More InternalSnap Fit Wire Retainers, now U.S. Pat. No. 7,075,007, which is acontinuation in part of application Ser. No. 11/100,250 filed Apr. 6,2005 for Snap In Electrical Connector Assembly With Unidirectional WireConductor Retainer Ring, now U.S. Pat. No. 7,064,272, which is acontinuation in part application of application Ser. No. 10/939,619filed Sep. 13, 2004 for Electrical Connector With Frustro Conical SnapFit Retaining Ring, now U.S. Pat. No. 6,916,988 B1, each of which isincorporated herein by reference.

FIELD OF THE INVENTION

This invention is directed to a further advancement in the field ofelectrical connector assemblies having a snap fit retaining ringcircumscribing the outlet end of a connector body for effecting a snapfit connection to an electrical box of the types described in U.S. Pat.No. 6,860,758, U.S. Pat. No. 6,935,891. More specifically, thisapplication is directed to further improvements in duplex typeelectrical connector assemblies.

BACKGROUND OF THE INVENTION

Electrical connectors are commonly used for attaching electricalconductors, cables, wires, electrical metal tubing (EMT) or the like toan electric box, e.g. a junction box, outlet box, switch box, fuse box,or other similar type of electric box or panel. Such known electricalconnectors are either of a type that are secured to an electric box by athreaded lock nut or by means of a conventional circular snap fitretaining ring of the type disclosed in U.S. Pat. Nos. 6,860,758;6,444,907; 5,189,258; 5,266,050; 5,171,164; 2,744,769 and 1,483,218 forexample. Reference is also made to U.S. Pat. No. 6,768,057 which isdirected to a right angle type connector formed of a pair of sheet metalstampings fitted together and secured to an electrical box with a snapfit arrangement.

Also known are connectors formed as connector caps which are adapted tobe fitted over the end of a conductor, cable or wires, such as disclosedin U.S. Pat. No. 4,880,387. Various other known efforts to facilitatethe connection of an electrical conductor to an electric box areevidenced by U.S. Pat. Nos. 6,043,432; 6,080,933; 6,114,630; 6,133,529;6,194,661; 6,335,488; 6,352,439; 6,355,884; 6,444,907; 6,555,750;6,604,400; 6,670,553; 6,737,584; 6,682,355; 6,780,029 and 6,849,803.

Notwithstanding the extensive background relating to electricalconnectors, continuing efforts are being made to improve, simplifyand/or reduce the cost and/or complexity of the known connectors in aneffort to advance the electrical connector art. This disclosure isdirected to such efforts.

SUMMARY OF THE INVENTION

An object of this invention is to provide a duplex type electricalconnector assembly having an integral or unitary connector body providedwith an outer frustro-conical retainer and an internal unidirectionalcable retainer.

An object of this invention is to provide an electrical connector with afrustro-conically shaped external retaining ring having a leading edgeand a trailing edge and integrally formed outwardly sprung locking tangsthat can be readily connected to a knock-hole of an electric box, panelor enclosure with a snap-fit wherein the trailing edge functions as theelectrical ground between the electrical box and the connector assembly.

Another object of this invention is to provide for an electricalconnector assembly that includes an electrical connector body having anoutlet end with a frustro-conical outer surface for receiving thereon acomplementary frustro-conical retaining ring that is readily fitted toand retained on the outlet end portion of the connector body.

Another object is to provide a connector assembly comprising a connectorbody having an outlet end free of any locking ring retaining flange andan associated externally circumscribing snap fit retainer circumscribingthe flangeless outlet end in a secured manner.

Another object is to provide a retaining ring, adapted to be fitted ontothe outlet end of an integrally formed duplex connector body whereby theretainer ring is frustro-conical in shape having a first series of tangsfor securing the connector body to an electrical box and a trailing edgeor tang for affecting a positive electrical ground with an associatedelectrical box.

Another object is to provide an electrical connector assembly having aconnector body with a frustro-conical outer retainer ring circumscribingthe outer surface of the connector body outlet end and having aconductor retainer in the form of a saddle connected to the connectorbody with a cable retaining strap hingedly connected to one end of thesaddle for securing either a nonmetallic or armor metal clad cablethereto.

Another object of this invention is to provide a strap type electricalconnector having a cable retainer in the form of a saddle for supportinga conductor, wire, or cable thereon and a readily detachable straphingedly connected to one end of the saddle in a manner that prohibitsunintentional detachment of the strap from the saddle.

Another object of this invention is to provide a simplified duplexconnector assembly having a connector body integrally formed consistingof a suitable metallic alloy defining at least a pair of parallelpassageways arranged to receive and retain therein a unidirectionalcable retainer in a predetermined oriented position, and having an outerfrustro-conical retainer for snap fitting the duplex connector to anelectric box or panel.

Another object is to provide a duplex type electrical connector assemblythat is relatively simple to fabricate, positive in operation, andeconomical to produce and sell.

The foregoing objects and other features and advantages are attained byan electrical duplex connector assembly that includes an integrallyformed connector body having a single outlet end adapted to be securedto a knock-out hole of an electric box or panel, and having at least apair of passageways defining an inlet end. A radially outwardlyextending flange circumscribes the outlet end of the integral connectorbody to function as a stop to limit the insertion of the outlet endportion of the integral connector body through the knockout hole of anelectric box or panel. The outlet end portion of the connector body isprovided with an outer surface that converges or tapers inwardly towardthe outlet opening thereof. Formed on the surface of the outlet endportion are one or more retaining lugs, which may be circumferentiallyspaced about the outlet end portion. A frustro-conically shaped,snap-fit retainer is fitted onto the outlet end portion of the connectorbody.

The frustro-conical retainer is formed from a blank of sheet material,e.g. spring steel or the like, having a cruciform shape that includes aface portion or simply a central opening wherein the radiating arms ofthe cruciform blank are disposed about the face portion or centralopening to define a frustro-conical ring or cup shape. The retainer ringor cup so formed is provided with blanked out or die cut tangs to defineoutwardly bent locking tangs. The trailing edge of the frustro-conicalring or cup provides for electrical grounding in the assembly of theelectrical connector to an electric box or panel.

The frustro-conical ring so formed also has a slot adapted to receive aretaining lug when the retaining ring is fitted onto the outlet end ofthe connector body so that the free or trailing edges of the ring or cupdefine a grounding edge or tang that engages the inner periphery of theknockout hole of an electric box or panel for effecting positiveelectrical continuity and grounding.

To form the retaining ring, the cruciform arms are arranged to be foldedrelative to the central opening or face forming portion thatcircumscribes the central opening, to define a unitary frustro-conicallyshaped cup-like member or ring to compliment or be fitted onto theoutlet end portion of the connector body. The retaining ring thus formedis fitted over or onto the outlet end portion of the connector bodywhereby the retaining slot formed in the ring is adapted to receive thecomplementary retaining lug formed on the surface of the outlet endportion for retaining or securing the ring on the outlet end portion ofthe connector body.

With the construction described, the connector assembly can be readilyinserted through the knockout hole of an electric box wherein thelocking tangs will initially be flexed inwardly to pass through theknock-out hole of an electric box, and then spring outwardly to lock theconnector assembly to the electric box or electric support panel withthe trailing or grounding edge or tang of the retaining ring beinginherently biased so as to be urged against the internal periphery ofthe knockout hole due to the frustro-conical configuration of theretaining ring to effect a positive electric ground as a result of theinherent resiliency of the respective grounding edge or tangs and thematerial from which they are formed.

This invention further contemplates providing the inlet end of theconnector with a unidirectional cable or conductor retainer disposedwithin each of the inlet passageways in a predetermined orientedrelationship therein.

IN THE DRAWINGS

FIG. 1 is an exploded perspective view of the electrical connectorassembly.

FIG. 2 is a plan view of the blank from which the outer retaining ringof the present invention is formed.

FIG. 3 is a detail front view of the outer retainer ring.

FIG. 4 is a detail top plan view of the outer retainer ring of FIG. 3.

FIG. 5 is a detail view of FIG. 4 rotated 90°.

FIG. 6 is a sectional view of the outer retainer ring taken along line6-6 on FIG. 3.

FIG. 7 is a side view of the connector assembly illustrating thealignment thereof relative to the knockout opening of an electric box.

FIG. 8 is a section side view illustrating the connector assemblysecured to an electric box, taken along line 8-8 on FIG. 10.

FIG. 9 is a sectional view taken along line 9-9 on FIG. 10 and rotated90°.

FIG. 10 is a fragmentary front view of the connector assembly secured toan electric box as viewed from the electrical box.

FIG. 11 is an exploded perspective view of a modified form of theinvention.

FIG. 12 is a sectional side view of the modified form of the inventionof FIG. 11.

FIG. 13 is a top plan view of the blank from which the internal wireconductor retainer is formed.

FIG. 14 is a fragmentary top view of a portion of the blank forming theinner retainer sleeve or ring.

FIG. 15 is an end view of the inner wire conductor retainer ring orsleeve.

FIG. 16 is a top view of the inner retainer ring or sleeve of FIG. 15.

FIG. 17 is a section view taken along 17-17 on FIG. 16.

FIG. 18 is a side view of the inner retainer ring or sleeve.

FIG. 19 is a sectional side view of still another embodiment.

FIG. 20 is a perspective view of a further embodiment of the invention.

FIG. 21 is an exploded perspective view of the embodiment of FIG. 20.

FIG. 22 is a top plan view of the embodiment of FIG. 20 having partsthereof broken away.

FIG. 23 is a sectional view taken along line 23-23 on FIG. 22.

FIG. 24 is the interior plan view of one section of the connectorhousing of the embodiment illustrated in FIG. 20.

FIG. 25 is an outer end view of FIG. 24.

FIG. 26 is an end view of the connector housing section of FIG. 24.

FIG. 27 is a sectional view of the housing section taken along line27-27 on FIG. 26.

FIG. 28 is an inside plan view of the complementary housing section ofthe embodiment illustrated by FIG. 20.

FIG. 29 is an end view of FIG. 28.

FIG. 30 is an inlet end view of FIG. 28.

FIG. 31 is a sectional view taken on line 31-31 on FIG. 30.

FIG. 32 is a sectional view taken on line 32-32 on FIG. 28.

FIG. 33 is an exploded perspective view of still another modification ofthe invention.

FIG. 34 is a top plan view of the embodiment of FIG. 33.

FIG. 35 is a right end view of FIG. 34.

FIG. 36 is a sectional view taken along line 36-36 on FIG. 35.

FIG. 37 is a perspective of a partially exploded view of anotherembodiment of the disclosed invention.

FIG. 38 is a perspective view of another modified form of the disclosedinvention illustrated without the outer retainer ring.

FIG. 39 is a perspective exploded view of a modified form of theinvention.

FIG. 40 is an exploded perspective view of another embodiment of theinvention.

FIG. 41 is a partial sectional side view of the embodiment of FIG. 40having parts shown in section.

FIG. 42 is a side sectional view of the embodiment of FIG. 41 showingthe connector assembly attached to a knockout hole of an electric box orpanel.

FIG. 43 is a fragmentary side view similar to FIG. 42 rotated 90° toillustrate the locking position of the locking tangs relative to anelectric box or panel.

FIG. 44 is a detail perspective view illustrating the assembly ofhinging the clamping strap to the support saddle.

FIG. 45 is a perspective view of a modified strap type electricalconnector.

FIG. 46 is an exploded perspective view of a modified duplex connectorembodying the invention.

FIG. 47 is the front or outlet end view of the duplex connector body ofFIG. 46.

FIG. 48 is the rear or inlet end view of the duplex connector body ofFIG. 46.

FIG. 49 is a top plan view of a duplex connector body of FIG. 46.

FIG. 50 is a sectional side view of the electrical duplex connectorassembly of FIG. 46 in the assembled position of the component parts.

FIG. 51 is a sectional view on a reduced scale of the connector bodytaken along section line 51-51 on FIG. 46.

DETAILED DESCRIPTION

Referring to the drawings, there is shown in FIG. 1 an electricalconnector assembly 10. The connector assembly 10 includes a connectorbody 11, which is usually formed as a metal casting, e.g. zinc or othersuitable metallic alloy. The connector body 11 is formed with an inletend portion 11A and an outlet end portion 11B and having a bore 12extending therethrough. Intermediate the connector body 11 or betweenthe inlet end portion 11A and outlet end portion 11B there is provided aradially outwardly extending flange 13 which functions as a stop tolimit the amount that the connector body 11 may be inserted through theknockout hole 14 of an electric box or panel 15, as noted in FIG. 8.

As shown in FIGS. 1 and 8, the outer surface S of the outlet end portion11B slopes, tapers or converges toward the outlet opening 16 whereby theouter surface S of the outlet end portion 11B has a generallyfrustro-conical configuration. Formed on the surface S of the outlet endportion 11B is an outwardly projecting retainer lug 17. In theillustrated embodiment, two such lugs 17 are shown disposed 180° apartabout the outer circumference of the outlet end portion 11B.

The connector assembly 10 also includes a snap fit retaining ring 18. Inaccordance with this invention, the retaining ring 18 is integrallyformed from a blank 19 of spring steel material. As best seen in FIG. 2,the blank 19 is initially formed or stamped to define a generallycruciform shape. The cruciform shape is provided with a face portion 20having central opening or hole 20A and having four generally radiallyextending arms defining two pairs of oppositely disposed arms AA and BB.

As illustrated in FIG. 2, the opposed pair of arms AA are each providedwith a retaining slot 21. The opposed pair of arms BB, as best seen inFIGS. 2 and 9, are blanked or formed to define a locking tang 22 and toeither side thereof the trailing edge of the retaining ring defines anelectrical grounding tang 23, 23. As shown, the locking tang 22 isslightly shorter than the adjacent grounding tangs 23, 23. Thearrangement is such that the free end of the locking tangs 22 are sprungoutwardly and formed so as to engage the inside surface of the electricbox 15 in the assembled portion, as best seen in FIG. 9, to secure theconnector assembly 10 to the electric box 15 and prohibit anyunintentional withdrawal of the connector assembly 10 from theelectrical box 15, whereas the free ends or trailing edges of thefrustro-conical ring define the grounding tangs 23 that are biased inengagement with the internal periphery of the knockout hole 14. Also,the free edge or end 24A of arms A,A in the assembled position will alsofunction as electrical grounding tangs, as noted in FIG. 8.

In forming the retaining ring 18 from blank 19, the respective arms A,Aand B,B are subjected to a series of progressive bending dies which willgradually bend the respective arms about a foldline f, which defines theface or front portion 20, whereby arms A,A and B,B form a cup havingcircumscribing frustro-conical or outwardly flaring sides to define afrustro conical ring 18 which complements the conical surface S of theleading or outlet end portion 11B, as seen in FIG. 1. In doing so, thelocking tangs 22 are cantileverly and outwardly bent or displacedrelative to the surface of the frustro-conical ring at a slightlygreater outwardly angle or slope than the adjacent grounding edge ortangs 23 and the slope of arms A,A. With the retaining ring 18 soformed, it can be readily fitted onto the outlet end portion 11B wherebythe inherent resiliency of the arms A,A will cause the retainer slots 22to snap fit onto the retaining lug 17 when slots 21 are placed inalignment with lugs 17. The arrangement is such that the retainer ring18 will be firmly and positively secured to the outlet end portion 11Bas seen in FIG. 8. Yet, due to the inherent resiliency of the materialof the retaining ring 18, it can be easily detached from the outlet endportion 11B when removal is desired, without destroying the ring 18 bylifting arms A,A free of the retaining lugs 17.

It will be understood that, if desired, the opening 20A may be enlargedto the diameter of the foldline f, in which case the arms A,A and B,Bmay be gradually bent about the periphery of the enlarged opening,thereby eliminating the face portion 20.

With the retainer ring 18 properly secured to the outlet end 11B of theconnector body 11, the connector assembly 10 can be readily secured toan electric box 10 by simply aligning the assembly 10 with a knockouthole 14, as best seen in FIG. 7, and inserting the leading or outlet endportion into the knockout hole 14 until the flange 13 engages the outerside of the electric box 15. In doing so, the tangs 22, 23 and the freeends 24 of arms A,A, respectively, will depress inwardly to permitinsertion of the assembly 10. When the assembly is fully seated in theknockout hole 14, the locking tangs 22 will normally spring outwardly tosecure the assembly 10 to the electric box 15, as noted in FIG. 9. Theinherent resiliency of the grounding tangs 23, 23 and the free end oredge 24A of arms A,A are normally biased in engagement with the internalperiphery of the knockout hole 14 to ensure a positive electrical groundwith the electric box 15. The engagement of the free end 24A of arms A,Aand grounding tangs 23, 23 against the inner periphery of the knockouthole 14, as noted in FIG. 8, further ensures the firm securing of theretaining slot 21 with the retaining lugs 17, so as to prohibit anydisengagement of the outer retaining ring 18 from the connector body 11.

It will be understood that the wire conductor 25 may be secured to theconnector assembly 10 either before or after the assembly 10 has beensecured to the electric box 15. In the illustrated embodiment, theconductor wire 25 is simply inserted into the inlet end portion 11A andsecured in position by a suitable securing means. In the illustratedembodiment of FIG. 1, the securing means is illustrated as a set screw26. However, it will be understood that other forms of securing means,including some of the securing wire conductor retaining means disclosedherein, may be used in lieu of a screw.

From the foregoing, it will be apparent that the disclosed connectorassembly is quite novel and simple in construction. The snap fitretaining ring 18 can be simply formed from a cruciform shaped blank 19of spring metal whereby the opposed radially extending arms A,A and B,Bcan be readily formed into a cup having a generally frustro-conicallyshaped sidewalls complementing the slope of the outlet end portion 11A,and whereby the outer retainer ring 18 can be readily secured to theconnector body simply by the inter-engagement of slots 21 with itscomplementary lugs 17.

In the assembled position, the outer retainer ring 18 is positivelysecured to the connector body in a manner to prohibit any unintentionalseparation. Also the tangs 22 and 23, which are formed integral withring 18, are shaped and formed so that the locking tangs 22 secure theassembly 10 to an electric box 15 while the grounding tangs 23 ensure apositive electrical ground of the assembly 10 with the associatedelectric box 15.

FIGS. 11 to 19 illustrate various views of a modified form of theinvention which are described in application Ser. No. 11/100,250 filedApr. 6, 2005, now U.S. Pat. No. 7,064,272, for Snap In ElectricalConnector Assembly With Unidirectional Wire Conductor Ring, which isincorporated by reference herein.

In the embodiment illustrated in FIG. 11, the connector assembly 30includes an internal wire retainer 39 in the form of a ring, cylinder orsleeve which is fitted to the bore 32B of the connector body 31, andwhich retainer 39 functions as a unidirectional retainer means arrangedto permit a wire conductor to be readily inserted and secured thereinto,and which will resist any applied force imparted to the wire conductorin the opposite direction to prohibit any unintentional separation ofthe wire conductor from the connector body 31. Wire conductor, as usedherein, means any wire, cable, helical wound metal covering or sheath(BX) wire, plastic sheath wire conductor and the like.

Referring to FIGS. 13 to 15, the internal retainer 39 is preferablyformed from an elongated blank 40 of spring steel. The retainer blank40, as best seen in FIG. 13, comprises an elongated generallyrectangular blank having a longitudinal leading edge 40A, a trailingedge 40B and opposed end edges 40C and 40D. End edge 40C is providedwith a pair of spaced apart notches 41, 41 and a projecting tongue 42.The other end edge 40D of blank 40 is provided with a pair of projectingtongues 43, 43 arranged to complement notches 41, 41 and a complementarynotch 44 for receiving tongue 42 in the formed or rolled position of theretainer sleeve 39, as shown in FIG. 18.

Blanked, lanced, cut or stamped out of the plane of blank 40 are one ormore tangs 45. In the form of the invention as shown in FIG. 13, tangs45 are formed out of the plane of the blank. The respective tangs 45 arebifurcated to define a pair of finger tangs 45A, 45A longitudinallyspaced along the longitudinal axis of the blank 40 at a distance, which,when the blank 40 is rolled to form the retainer sleeve 39, therespective pairs of finger tangs 45A are oppositely disposed, as bestseen in FIG. 15.

As shown in FIGS. 15 and 18, the respective finger tangs 45A, 45A areinwardly bent from the plane of the retainer sleeve 39. In theillustrated embodiment, the respective finger tangs are provided with apair of intermediate transverse fold lines F₁ and F₂ whereby the freeend of the respective finger tangs is directed toward the longitudinalaxis of the sleeve 39, as shown in FIG. 18.

Referring to FIG. 15, it will be noted that the cable retainer sleeve isor may be provided with a flattened portion 46 on one side thereof.

The connector body of FIGS. 11 and 12 may be formed with an internalcomplementary flat surface along a portion of the inner circumferencethereof. The arrangement is such that the retainer sleeve 39, wheninserted into the inlet end 31B of the connector body, is oriented sothat the flattened surface 46 of the sleeve 39 complements the internalflattened surface 47 of the connector body. The orientation is such thatthe opposed finger tangs 45A are oppositely disposed to firmly grip awire conductor therebetween, e.g. an armored conductor or other coveredconductor, as shown in FIG. 12.

The outer circumference of the inner retainer sleeve or ring 39 isproportioned so that it can be press fitted or frictionally fitted intothe inlet end 31B of the connector body 31 by a force sufficient tofirmly secure the inner retainer ring or sleeve 39 within the inlet endso as to prohibit any separation of the retainer ring or sleeve 39 fromthe inlet end of the connector body. The complementary flattenedsurfaces 46 of the internal sleeve 39 and 47 of the inlet end of theconnector body insures proper orientation of the internal sleeve 39within the inlet end of the connector body.

FIG. 14 illustrates a fragmentary portion of the blank 40 to show anintermediate step in forming the tang fingers 45A, 45A so that when theformed blank 40 is rolled to form the internal retaining sleeve, thetang fingers will be disposed in parallel as seen in FIGS. 15 and 16.This is attained by fold line F₃ which is disposed at an angle, as notedin FIG. 14, so that when the blank is rolled to form the internalretaining sleeve 39, the tang fingers 45A, 45A will be disposed inparallel. The free ends 45B of the respective fingers 45A are angularlyoffset to engage the grooves of an armored conductor, as noted in FIG.12 or other covering sheath of a wire conductor that will resist a forceattempting to effect separation of the conductor from the connectorassembly. The respective free ends 45B may also be laterally offset sothat an armored conductor may be threadedly connected to the internalsleeve 39, as well as by simply inserting the armored covered conductorinto the retainer sleeve to effect a snap fit connection.

FIGS. 20 to 32 are directed to a further modification of the disclosedinvention. As best seen in FIGS. 20 and 21, the connector assembly 60includes a housing or connector body 61 having an outlet end 61A and aninlet end 64 connected to the outlet end 61A by a transition section 68,68A, preferably formed as casting of any suitable metal or alloymaterial, e.g. zinc, aluminum and the like. While the inlet end 64 ofthe connector body 61 is illustrated as a duplex inlet end, it will beunderstood that the inlet end may be formed to accommodate more than twoseparate wire conductors, cables or the like.

The outlet end 61A and the external frustro-conical ring 76circumscribing the outlet end 61A are similar in structure hereinbeforedescribed with respect to FIGS. 1 to 10. A more detailed description ofthe embodiments disclosed in FIGS. 20 to 32 is set forth in applicationSer. No. 11/100,250 filed Apr. 6, 2005 for Snap In Electrical ConnectorAssembly With Unidirectional Wire Conductor Retaining Ring, now U.S.Pat. No. 7,064,272, which is incorporated herein by reference.

With the connector body of FIG. 20 illustrated, it will be noted thatthe connector assembly 60 can be readily secured to an electric box orpanel simply by inserting the leading or outlet end 61A through aknockout hole of a panel or electrical box so as to be readily securedthereto with a snap fit as hereinbefore described. With the arrangementdescribed, the respective wire conductors or cables 80 can be readilyattached to the trailing or inlet end of the connector assembly 60 witha simple snap fit, as described in the said application Ser. No.11/100,250 filed Apr. 6, 2005, now U.S. Pat. No. 7,064,272, which isincorporated by reference herein.

From the foregoing, it will be noted that the connector assembliesdisclosed in FIGS. 1 to 32 utilize a frustro conically shaped outerretainer ring which is uniquely secured to the leading end of aconnector body, with securing tangs and grounding tangs arranged toeffect both a positive securement of the connector assembly to aknockout hole of an electric box or panel and a positive electricalground. In association with an external frustro conical retaining ring,the disclosed embodiments include a trailing or inlet end constructed toreceive an associated wire or conductor retainer in each inlet end forsecuring a wire conductor thereto by a snap fit in the inlet end of theconnector body. It will be understood that the described electricalconnector bodies may include one or more wire or conductor cablereceiving chambers formed in the inlet end thereof, depending upon thenumber of wire conductors one may wish to connect to the inlet end of aconnector body.

FIGS. 33 to 36 illustrate a further embodiment of the invention. Theconnector assembly 300, as illustrated in FIGS. 33 and 36, includes aconnector body 301 formed as a unitary casting of any suitable metal oralloy, e.g. zinc and the like. The embodiment of FIG. 33 differs fromthat of FIG. 20 in that connector body 301 is formed as a unitarycasting rather than as separable parts as illustrated in FIG. 20. A moredetailed description of the embodiment of the connector assembly ofFIGS. 33 to 36 is set forth in application Ser. No. 11/403,099 filedApr. 12, 2006, for Snap Fit Electrical Connector Assembly WithFrustro-Conical Retainer Ring And Internal Unidirectional Snap Fit WireConductor Retainer, now U.S. Pat. No. 7,151,223, which is incorporatedby reference herein.

FIGS. 37, 38 and 39 illustrate further modified embodiments of theinvention which are disclosed in the co-pending application Ser. No.11/501,131 filed Aug. 8, 2006 for Electrical Connector With OuterRetainer Ring And Unidirectional Conductor Retainer, which is alsoincorporated by reference herein, and need not be repeated herein.

FIGS. 40 to 49 are directed to other modified embodiments of theinvention. FIGS. 40 to 49 are directed to a strap-type electricalconnector 500 for securing either nonmetallic cables or armor or metalclad cables thereto, as will be described herein.

As best seen in FIGS. 40-49, the illustrated strap type connector 500includes a connector body 501 having an outlet end 502 terminating in anoutlet opening 503. Opposite the outlet opening 503, the connector body501 is provided with an inlet opening 504. Circumscribing the connectorbody between the outlet opening 503 and the inlet opening 504 is aradially outwardly extending flange 505 which serves as a stop to limitthe distance the outlet end portion of the connector body 501 may beinserted through a knockout hole or opening 506 of an electric box orpanel 507. The outer surface “S” of the outlet end 502 slopes orconverges inwardly toward the outlet opening 503.

Circumferentially spaced about the outlet end 502 of the connector body501 are one or more radially outwardly projecting retaining lugs 508. Inthe illustrated embodiment, two such retaining lugs 508 are provided180° apart.

Secured to the outlet end 502 of the connector body and circumscribingthe outlet end 502 is a frustro-conical snap fit retainer or retainerring 509, similar to the frustro-conical retainer ring hereinbeforedescribed with respect to FIGS. 1 to 5 herein. As best seen in FIG. 40,the frustro-conical, snap-fit, retainer 509 includes a front opening 510circumscribed by rearwardly and outwardly sloping locking tangs 511 andgrounding tangs 512 and 513. Grounding tangs 513 are provided withretaining slots 514 arranged to receive the retaining lugs 508 whenfitted onto the outlet end 502 of the connector body 501, ashereinbefore described.

Connected to the connector body 501 adjacent the inlet opening andforming an integral part of the connector body 501 is a cable supportsaddle 515 which extends about a circumferential portion of the inletopening 504, e.g. between approximately 120° to 180° about the inletopening 504. As shown, the cable support saddle 515 is a curvilinearextension of the inlet opening 504 terminating in laterally outwardlyextending ears or lobes 515A and 515B. As best seen in FIG. 40, ear orlobe 515A has a hinge slot 516 formed therein and ear or lobe 515B isprovided with an internally threaded hole 517.

Hingedly connected to ear or lobe 515A is a clamping strap 518. As bestseen in FIG. 40, the clamping strap 518 is provided with a readilydetachable hinge structure 519 which is angularly formed relative to theplane of the strap 518 so as to be received in the hinge slot 517 whenconnected to the saddle 515. According to this invention, the hingestructure 519 terminates laterally outwardly extending foot portion 520.

In accordance with this invention, the foot portion 520 of the hingestructure 519 is provided with a width “W” which is slightly greaterthan the width “w” of the hinge slot 516. The arrangement is such thatthe clamping strap 518 must be skewed or angled relative to the hingeslot 516 for inserting the foot portion 520 through the hinge slot 516for connecting the clamping strap 518 to the ear or lobe 515A. When soconnected, the clamping strap 518 is free to pivot relative to thesaddle 515 between a cable clamping and unclamping position withoutcausing the clamping strap 518 to become detached from the saddle 515.To effect detachment of the clamping strap 518 from the ear or lobe515A, one must intentionally skew or angle the clamping strap 518relative to the hinge slot 516 to effect the removal of the clampingstrap 518 from the saddle.

The other end of the clamping strap 518 is provided with a strap hole521 for receiving a fastener, e.g. a screw 522 for securing the clampingstrap 518 to the ear or lobe 515B so that the cable is firmly clampedand secured between the saddle 515 and the clamping strap 518.

To insure a positive gripping of the cable between the saddle 515 andthe clamping strap 518, an intermediate portion of the clamping strap isprovided with a depression 523 that will “bite” or exert a positivefrictional force on the cable, when secured in the clamping position(FIG. 41) so as to prohibit the cable of being pulled free or becomeaccidentally detached from the connector body.

As shown, the connector body 501 and connected saddle 515 is preferablyformed as a metal casting, e.g. zinc or other suitable metallic alloy.The strap electric connector as illustrated in FIGS. 40 to 44 ispreferably used for securing either a non-metallic cable or romex typeconductor to an electric box or panel.

By slightly modifying the shape of the clamping strap, the describedstrap type electric connector may be readily adapted for connecting anarmored, or metal clad cable, to an electric box or panel.

FIG. 45 illustrates a modified strap type electrical connector assembly600 for use in securing an armor or metal clad cable. As shown in FIG.45, the strap type electrical connector assembly 600 is provided withclamping strap 618 having an intermediate curvilinear portion 618Ashaped to compliment the roundness of a metal clad cable, e.g. a BXcable. One end of the armored cable strap is provided with a hingestructure 619, 620 similar to the hinge structure 519, 520 hereinbeforedescribed, whereby the armored cable strap can be hingedly connected tothe hinge slot 616 of the associated saddle 615. The other end of thearmored cable strap 618 is provided with a hole or opening 621 forreceiving a fastening screw similar to that described with respect toFIG. 41. In all other respects, the function and structure of the strapconnector 600 is similar to that described with respect to FIGS. 40 to44, and need not be repeated.

From the foregoing description, it will be noted that the armored cablestrap 618 can be readily interchanged for the non-metallic cable strap518 depending upon the type of cable to be secured by the describedconnector body.

It will be apparent that the principle components described herein, viz.the external frustro-conical retainer rings, the connector bodies andthe differently described wire conductor retainers, are rendered readilyinterchangeable with respect to any of the complementary correspondingcomponents of the various embodiments described herein.

It is to be further noted that the frustro-conical retainer ring, asdescribed herein with respect to the various embodiments disclosed,achieves the further advantage of ensuring positive electrical groundingof the described connector assemblies to an electrical box or paneldespite the varying allowable diameter tolerances a knockout hole mayhave, as permitted by the allowable codes or electrical standards, dueto the inherent resiliency and shape that a frustro-conicalconfiguration allows, as described herein.

Referring to FIGS. 46 to 51, there is disclosed a further improvement ofthe invention describe herein. FIG. 46 illustrates an exploded view of aduplex type connector assembly 650 that includes a connector body 651having a single outlet end portion 651A and a duplex inlet end portion651B. As shown, the inlet end portion 651B includes a pair of parallelpassageways or bores 652, 653 that are in communication with the outletend portion 651A. Between the inlet end portion 651 and the outlet endportion 651A is a transition section 651C, which diverges toward theoutlet end opening 354. The respective passageways or bore are separatedby a partition wall 655 having opposed vertical surfaces 655A, 655B, asviewed in FIGS. 46-48.

As hereinbefore described, the outlet end portion 651A which defines anoutlet opening 654 is provided with a tapered outer surface S whichconverges toward the outlet opening 654. Circumferentially spaced aboutthe outlet opening and extending radially outward relative to thesurface S of the outlet end portion 651A are opposed retaining lugs 656.A radially outwardly extending stop flange 657 circumscribes the outletend portion 651A adjacent to the transition section 651C, whichfunctions as a stop to limit the amount the connector body may beinserted into a knockout hole of an electric box or panel, as hereinpreviously described. In this form of the invention, the connector body651 is constructed so that it can be readily formed as a unitary castingfrom a suitable moldable metal alloy, e.g. zinc, aluminum and the like.Such integrally constructed connector body obviates the prior practiceof constructing a connector body of multiple parts which requiredassembly.

Circumscribing the outer surface S of the outlet end portion 651A is afrustro-conical outer retainer 658 similar to that described withrespect to FIGS. 1 to 10, and which need not be repeated.

Disposed within each of the respective passageways or bore 662, 663 is awire or cable unidirectional retainer means. In the illustratedembodiment, the unidirectional retainer means is in the form of a sleeveor cylinder 659, 660 formed preferably from a blank of spring steel ashereinbefore described with respect to FIGS. 13 to 18. As described, therespective wire or cable retainers 659, 660 have a generally circularconfiguration except for a flattened or linear wall surface 659A, 660A,which is arranged to engage the adjacent vertical wall surface 655A,655B of the inlet end portion 655 when inserted into their associatedpassageways or bore 652, 653. The arrangement is such that theorientation of the respective wire or cable retainers 656, 660 relativeto their respective passageways or bores are predetermined. Aspreviously described, the respective wire or cable retainers areproportioned and sized so as to be press fitted or frictionally fittedwithin their corresponding bore or passageway 653, 653 in a manner towithstand any unintentional separation of the cable retainer from itscorresponding bore. In all other respects, the construction and functionof the internal wire or cable retainer is similar to that hereinbeforedescribed with respect to FIGS. 13 and 18.

As noted in FIGS. 46 and 50, the connector assembly 650 includes abushing 661, constructed preferably of a plastic non-conducting materialarranged to be inserted in the outlet opening 654 of the connector body651. The bushing 661 includes a cylindrical body portion 661A sized andshaped so as to complement the internal surface of the outlet opening654 with a friction or press fit. The leading end of the bushing 661 isprovided with a radially outwardly extending flange 661B which functionsas a stop to limit the insertability of the bushing 661 within theoutlet end opening 654.

In the assembled position of the respective component parts, it will benoted that the bushing 661 is inserted and secured within the outlet endopening 654 before the frustro-conical external retainer 650 is securedabout the outlet end portion 651B of the connector body. Thus, theengagement of the frustro-conical retainer 650 with the retainer lugs656 insures that the bushing 661 is prevented from being separated fromthe outlet opening as it is firmly sandwiched between the outlet opening654 of the connector body 651 and the frustro-conical retainer 650secured to the outlet end portion 651B.

As the cable retainers 659, 660 are provided with forwardly inclinedretaining tangs 662, the respective cable or wire conductors 663 can bereadily secured thereto simply by inserting the cable or wire conductorinto the respective inlet passageways whereby the retaining tangs permitonly unidirectional insertion while resisting an opposing force appliedto the cable or wire conductor so as to prohibit any unintentionalseparation of the cable or wire conductor from the connector body 651.

The simplicity of a duplex connection having a unitary connector bodyconstruction provided with an outer frustro-conical retainer forsecuring the same with a snap fit locking arrangement to an electric boxor panel, and the ease by which a wire conductor can be secured to aconnector body utilizing the described internal cable retainers enhancesthe ease of manufacture and assembly of such connectors to result insubstantial savings of labor and costs for producing the same, whileenhancing the ease of use of such connectors in the field which furtheraids to minimize the time, effort and labor required to install thesame.

While the present invention has been described with respect to severalembodiments, it will be understood that various modifications may bemade without departing from the spirit or scope of the invention.

1. An electrical connector assembly comprising: a connector body havingan outlet end portion and an inlet end portion, said outlet end portiondefining an outlet opening, and said inlet end portion defining an inletopening, a non-conducting bushing having a cylindrical body portionfrictionally fitted within said outlet opening, said bushing having aradially outwardly extending flange that limits the insertability ofsaid cylindrical body portion within said outlet opening, afrusto-conical retainer circumscribing said outlet end portion, meansfor securing said frustro-conical retainer onto said outlet end portionso that said bushing is sandwiched between said frustro-conical retainerand said outlet opening, whereby said bushing is prevented from beingseparated from said outlet opening by said frustro-conical retainer, anda unidirectional cable retainer secured within said inlet end portion.2. An electrical connector assembly comprising: a connector body havingan outlet end portion and an inlet end portion, said outlet end portiondefining an outlet opening, and said inlet end portion defining an inletopening, a non-conducting bushing having a cylindrical body portionfrictionally fitted within said outlet opening, said bushing having aradially outwardly extending flange that limits the insertability ofsaid cylindrical body portion within said outlet opening, afrusto-conical retainer circumscribing said outlet end portion, meansfor securing said frustro-conical retainer onto said outlet end portionwhereby said bushing is sandwiched between said frustro-conical retainerand said outlet opening, a unidirectional cable retainer secured withinsaid inlet end portion, wherein said inlet end portion of said connectorbody defines a pair of inlet passageways, said passageways beingdisposed in side by side relationship within said inlet end portion, andhaving a common wall partition separating said side by side passageways,and a transition portion connecting said pair of passageways within saidinlet end portion in communication with said outlet end portion whereinsaid outlet end portion, inlet end portion defining said pair of inletpassageways, and said interconnecting transition portion beingintegrally connected to one another to define a unitary member.
 3. Anelectrical connector assembly as defined in claim 2 wherein said wallpartition having opposing flat wall surfaces that are parallel to oneanother.
 4. An electrical connector assembly as defined in claim 3wherein said frustro-conical, retainer includes a leading end, atrailing end and an intermediate portion therebetween, and said leadingend includes a face portion having a central opening disposed inalignment with said outlet opening whereby said bushing flange issandwiched between said face portion and said outlet end portion.
 5. Aduplex electric connector assembly comprising: a connector body havingan outlet end portion and an inlet end portion, said outlet end portiondefining a single outlet opening, said inlet end portion having at leasta pair of inlet passageways disposed in side by side relationship, apartition wall separating each of the inlet passageways, a transitionsection connecting said pair of passageways in communication with saidoutlet opening, said outlet end portion, inlet end portion, saidpartition wall and said transition sections being integrally formed as ametal casting, a radially outwardly extending stop flange circumscribingsaid connector body between said inlet end portion and said outlet endportion, an outer retaining ring circumscribing said outlet end portion,means on said outlet end portion for retaining said outer retainer ringonto said outlet end portion, said retaining ring including lockingtangs circumferentially spaced about the outer surface of said retainingring, said locking tangs being blanked and cantilverely bent out of thesurface of said outer retaining ring whereby the free ends of saidlocking tangs are directed toward said stop flange, conductor retainingmeans secured in each of said passageways for effecting unidirectionalinsertion of an electrical conductor into each of said passageways so asto prohibit unintentional separation of an electrical conductor fromsaid passageway, said conductor retaining means comprising a sleevefrictionally secured within its corresponding passageway, and each ofsaid sleeves having opposed inwardly angularly bent tangs directedtoward said outlet opening for permitting unidirectional insertion of anelectrical conductor into each of said passageways.
 6. A duplexconnector as defined in claim 5 and including a non-conducting bushingextending into said outlet end opening and said bushing is sandwichedbetween said outlet end opening and said outer retaining ring, wherebysaid bushing is prevented from being separated from said outlet endopening by said outer retaining ring.
 7. A duplex connector as definedin claim 5 further comprising: a linear wall surface formed on each ofthe sleeves comprising said conductor retainer means; and opposingvertical surfaces formed on said partition wall separating each of theinlet passageways, whereby said linear wall surfaces and said opposingvertical surfaces engage.
 8. A duplex electrical connector assemblycomprising: a unitary connector body integrally formed as a metalcasting having an outlet end portion, an inlet end portion and anintermediate transition section connecting said inlet end portion incommunication with said outlet end portion, said outlet end portionhaving an outlet opening, said inlet end portion having a pair of sideby side inlet passageways, each of said passageways having an inletopening, a partition wall disposed between said side by sidepassageways, said partition wall having opposed flat wall surfaces, aradially outwardly stop flange circumscribing said connector bodybetween said outlet opening and said passageways inlet openings, saidoutlet end portion having an outer surface sloping inwardly toward saidoutlet opening, a frustro-conical shaped outer retainer circumscribingsaid outer sloping surface, said frustro-conical outer retainer having aface portion having a central opening disposed in alignment with saidoutlet end opening, means for securing said frustro-conical outerretainer on said outer sloping surface, said frustro-conical outerretainer having a plurality of locking tangs formed out of said surfaceof said frustro-conical shaped outer retainer, said locking tangs beingoutwardly bent relative to said surface of said frustro-conicalretainer, and a cable retainer sleeve secured within each of saidpassageways, each of said cable retainer sleeve being generallycylindrical configuration with a flattened side portion, said flattenedside portion being disposed to complement said flattened surface of saidpartition wall in the assembled position, said cable retainer sleeveseach including opposed cable retaining tangs blanked out of the surfaceof its respective cable retainer sleeve, said cable retaining tangsbeing inwardly bent at an angle relative to the surface of saidrespective cable retainer sleeve in the direction of said outlet endopening whereby said cable retaining tangs permit insertion of a cabletherethrough and prohibits unintentional separation of a cabletherefrom, and a non-conducting bushing fitted into said outlet endopening whereby said bushing is sandwiched between said face portion ofsaid frustro conical retainer and said outlet end opening.
 9. Anelectrical connector assembly comprising: a connector body having anoutlet end portion and an inlet end portion, said outlet end portiondefining an outlet opening, and said inlet end portion defining an inletopening, a non-conducting bushing having a cylindrical body portionfrictionally fitted within said outlet opening, a frusto-conicalretainer circumscribing said outlet end portion, means for securing saidfrustro-conical retainer onto said outlet end portion, a unidirectionalcable retainer secured within said inlet end portion, wherein said inletend portion of said connector body defines a pair of inlet passageways,said passageways being disposed in side by side relationship within saidinlet end portion, and having a common wall partition separating saidside by side passageways, and a transition portion connecting said pairof passageways within said inlet end portion in communication with saidoutlet end portion wherein said outlet end portion, inlet end portiondefining said pair of inlet passageways, and said interconnectingtransition portion being integrally connected to one another to define aunitary member.
 10. A duplex electrical connector assembly comprising: aunitary connector body integrally formed as a metal casting having anoutlet end portion, an inlet end portion and an intermediate transitionsection connecting said inlet end portion in communication with saidoutlet end portion, said outlet end portion having an outlet opening,said inlet end portion having a pair of side by side inlet passageways,each of said passageways having an inlet opening, a partition walldisposed between said side by side passageways, said partition wallhaving opposed flat wall surfaces, a radially outwardly stop flangecircumscribing said connector body between said outlet opening and saidpassageways inlet openings, said outlet end portion having an outersurface sloping inwardly toward said outlet opening, a frustro-conicalshaped outer retainer circumscribing said outer sloping surface, saidfrustro-conical outer retainer having a face portion having a centralopening disposed in alignment with said outlet end opening, means forsecuring said frustro-conical outer retainer on said outer slopingsurface, said frustro-conical outer retainer having a plurality oflocking tangs formed out of said surface of said frustro-conical shapedouter retainer, said locking tangs being outwardly bent relative to saidsurface of said frustro-conical retainer, and a cable retainer sleevesecured within each of said passageways, each of said cable retainersleeve being generally cylindrical configuration with a flattened sideportion, said flattened side portion being disposed to complement saidflattened surface of said partition wall in the assembled position, saidcable retainer sleeves each including opposed cable retaining tangsblanked out of the surface of its respective cable retainer sleeve, andsaid cable retaining tangs being inwardly bent at an angle relative tothe surface of said respective cable retainer sleeve in the direction ofsaid outlet end opening whereby said cable retaining tangs permitinsertion of a cable therethrough and prohibits unintentional separationof a cable therefrom.